Coping Sled

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Project by Kent Shepherd posted 09-20-2010 07:00 PM 7507 views 7 times favorited 9 comments Add to Favorites Watch

This is a coping sled I made for my raised panel door shop. We use another machine for our standard
doors, but I built this while doing an entry door project for a church. We now use it for some of the specialty doors we do.

Aluminum and angle iron will hold up in production for years. Obviously you can use the same ideas and build cheaper from wood. Using metal is not as difficult as you might think. A good drill press will get you a long way.
I use a cheap metal cutting chop saw to cut angle iron. but a hack saws works also—although it makes me tired thinking about it.


9 comments so far

View PurpLev's profile


8553 posts in 4211 days

#1 posted 09-20-2010 07:05 PM

Thank you Kent! I think I have finally found a use for my 5/8” phenolic panel… it’s sitting there, just waiting for a purpose.

FYI, a jigsaw also works wonders on aluminum with a metal blade. it can also be installed inverted in a router table.

What brand of cutters do you guys use on your shapers?

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 3848 days

#2 posted 09-20-2010 07:28 PM

Sharon, we use a lot of different cutters. The ones here are Freeborn, which we used to use a lot until we went to insert tooling on many of our machines. I have those done at Texas Carbide in the Dallas area.

Your phenolic will work great. I generally use it for all my fences. Stays straight and lasts forever. Glad this helped.

Come to think of it, I believe I did use a jig saw also. It’s been years since I built it. My memory went a long time ago.


View Joe Lyddon's profile

Joe Lyddon

10809 posts in 4614 days

#3 posted 09-20-2010 07:29 PM

Looks good!

That angle iron etc. is good for solid 90* faces too…

Thank you…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View degoose's profile


7264 posts in 3917 days

#4 posted 09-20-2010 09:16 PM

Very useful project…

-- Don't drink and use power tools @

View Karson's profile


35209 posts in 4963 days

#5 posted 09-20-2010 10:05 PM

Kent: A greqt tool and jig.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Grumpy's profile


25847 posts in 4413 days

#6 posted 09-21-2010 03:43 AM

Nice jig Kent.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Rick  Dennington's profile

Rick Dennington

6778 posts in 3757 days

#7 posted 09-21-2010 06:42 AM

Hi Kent,
Hey…. stellar job on the coping sled….I’ve never seen one quite like that one you made…..
Very interesting concept, indeed….I think it’s great when someone can come up witha good plan.
I can see in your shutter business where it would pay off….last you for years….Nice going…...
Next time I get back down to Lubbock, we’ll hook up again…. I still want one of your mallets….. lol.

-- " There's a better way.....find it"...... Thomas Edison.

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 3848 days

#8 posted 06-02-2011 07:08 PM

Thanks August, I have had pretty good luck with the rubber on mine. What problems are you having? How much tension are you placing on the clamp? Have you replaced it with something else?

I know, lots of questions—just curious.


View reggiek's profile


2240 posts in 3832 days

#9 posted 06-02-2011 08:24 PM

Great jig…I’ve made several of these…..the biggest problem is making sure the clamping system does not bow or deform the base (thus throwing your stick out of alignment and making voids in the joint)...yet the clamp has to be strong enough to hold the stick steady as it feeds through the bit….I tried several different clamps and orientations using a wood base….I then tried making the base out of aluminum to allow the clamp a bit more pressure before the base would deform. As you mentioned above…the metal was not any harder to make then the wood…..although for my final build I did sandwich the aluminum base with 1/4” phenolic laminated ply to add stiffness and protection for my router table (and the stick itself).

-- Woodworking.....My small slice of heaven!

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